Applications for laminate web

ABSTRACT

A laminate web and several uses of the laminate web are disclosed. The laminate web comprises a first web, a second web joined to the first web at a plurality of discrete bond sites; and a third material disposed between at least a portion of the first and second webs. The laminate webs of the present invention are suitable for a variety of uses. Such uses include flexible carrying implement, medical applications, kitchen or bathroom implements, decorative coverings, home accent items, pet industry articles, fabric, fabric backings, edible materials, bedding applications, absorbent food pads, clean room wipes, tack cloths, and many other uses.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application is: a continuation-in-part and claims priorityof prior application PCT International Application Ser. No. US00/34746(Case 7897R2) which designates the US, will publish in English, and wasfiled Dec. 20, 2000 in the names of Curro et al.; and acontinuation-in-part and claims priority of prior application Ser. No.09/584,676 (Case 7897R2), filed May 31, 2000 in the names of Curro etal.; and a continuation-in-part and claims priority of prior applicationSer. No. 09/467,938 (Case 7897), filed Dec. 21, 1999 in the names ofCurro et al.

FIELD OF THE INVENTION

[0002] This invention relates to several uses and applications of amultilayer laminate web. In some embodiments, the central layer or theentire multilayer laminate web is apertured.

BACKGROUND OF THE INVENTION

[0003] Laminate webs formed by the joining of discrete webs in a layeredrelationship are well known in the art. For example, often laminatenonwoven webs are utilized in disposable absorbent articles such asdiapers and adult incontinence products. Such laminated webs can be usedas a topsheet, backsheet, or side panels. One example of a laminate webis a film/nonwoven laminate useful for a stretch side panel of adisposable diaper. Nonwoven/nonwoven laminates are also utilized toprovide additional bulk or softness to a web component. Likewise,film/film laminate webs can provide benefits by combining thecharacteristics of various films in a layered relationship. Laminatewebs can also be called composite webs.

[0004] Less common examples of laminate webs include laminates ofdissimilar materials. The materials may be dissimilar in mechanicaltensile properties, thermal properties, or visual/tactile properties.For example, a nonwoven web may be joined to a relatively stiff fabricto provide for a soft surface feel to the fabric. The dissimilarmaterials may be joined by melt bonding, adhesive bonding, ultrasonicbonding, and the like. Bonding methods are often determined by thematerials themselves, but often require adhesive bonding. For example, alaminate or composite of materials having widely differing meltproperties may require an adhesive layer between laminate layers. Evenmaterials having similar melt properties, such as nonwoven andthermoplastic film materials are often joined by adhesive for adequatebonding to prevent unwanted delamination. Although adhesive may benecessary, such processing methods can be expensive due to the additionof adhesive, and the resulting laminate is often relatively stiff,depending on the laminate materials and the level of adhesive added.

[0005] Often laminate webs are intended to combine properties of theconstituent layers to achieve synergistic benefits. For example,EP-B-715,571 issued to Wadsworth discloses a multilayered nonwovencomposite web intended for use as a substitute for a woven web such as atextile web. The web comprises at least a layer of thermoplasticman-made fibers and a layer of cellulose-based fibers. Thecellulose-based fiber layer is disclosed as thermally bonded to thethermoplastic man-made fiber layers at spaced apart locations. However,it appears that thermal bonding between both, or all, the layers isnecessary to produce the requisite bonding.

[0006] EP-A-112,654 issued to Haq, et al. discloses a laminatecomprising two sheets of nonwoven fabric or the like having sandwichedbetween them a solid core material which may be a highly porous,optionally liquid-containing, polymer. The two outer sheets are bondedto each other, without involving the core material, by means of aplurality of small, spaced bonding points, for example, spot-welds.Preferably the core material is in continuous sheet form and isperforated to accommodate the bonding points. However, it appears itwould present a significant processing problem to register theperforations of the core material in order to have the outer layersbonded therethrough.

[0007] For many purposes it is desirable to have an apertured nonwovenweb, the apertured web being characterized by a plurality of openings,or perforations, in the web. Such apertures can provide for an open meshappearance, as well as beneficial texture and cloth-like properties.Such apertured nonwoven webs can be made by methods known in the art.For example, EP-B-164,740 issued to Shimalla discloses an aperturednonwoven fabric comprising a web of thermoplastic fibers is described.The fabric is formed with a multiplicity of fused patterned regions andadjacent substantially non-fused regions, there being apertures formedwithin a plurality of the fused patterned regions but not within theadjacent regions. The fabric is produced by heat embossing a non-wovenweb of thermoplastic fibers at a temperature above the softening pointof the fibers whereby the regions of the web compressed by theprojections of the embossing means become fused, and immediatelythereafter drafting the embossed web so that apertures are formed in thefused patterned regions. However, it is not apparent that the methoddisclosed would produce a laminate of nonwoven webs, or a laminate ofdissimilar materials.

[0008] Another beneficial method of aperturing a nonwoven web, includinglaminates of nonwoven webs is disclosed in EP-A-852,483, issued toBenson et al. Disclosed is a laminate material having, for example, atleast one layer of a spunbonded web joined to at least one layer of ameltblown web, a bonded carded web, or other suitable material. Suchapertured webs are useful as the topsheet in a disposable absorbentarticle. However, this disclosure does not teach laminating webscomprising dissimilar materials (e.g., materials of different materialclasses or having differing material properties).

[0009] A perforated multilayer elastic coversheet comprising anintermediate elastic layer between upper and lower nonwoven layers isdisclosed in EP-A-784,461 issued to Palumbo. The upper and lower layersare connected to the intermediate layer only around the perimeters ofthe perforations. While providing an apertured, elastic laminate, it isnot apparent that the method disclosed could produce laminatescomprising thermally-dissimilar materials.

[0010] As mentioned, nonwoven webs are beneficial as components ofdisposable consumer products, such as diapers, incontinence briefs,training pants, feminine hygiene garments, and the like, as well as inwipes such as disposable wet wipes. However, used alone, such nonwovensare limited in the range of beneficial properties, including visual,tactile, strength or absorbent properties due to the limits of knownmethods of making, particularly as compared to woven or knittedmaterials. Importantly, laminates of nonwoven webs and other materialsfor use in disposable consumer products have heretofore been limited dueto processing limitations, including incompatible materials (e.g.,thermally dissimilar materials), cost considerations (e.g., adhesivelamination costs) or tactile properties (e.g., softness and visualaesthetics).

[0011] Nonwovens are also beneficial components of other consumerproducts, such as non-absorbent disposable garments, durable garments,automotive components, upholstered furniture, filtration media, andother consumer or commercial goods. Nonwovens used in these and otherapplications benefit from their wide range of visual and tactileproperties. However, in many cases, the nonwovens used could benefitfrom being combined with other dissimilar materials in a composite web.

[0012] Accordingly, it would be desirable to have laminate webs ofdissimilar material properties which are not dependent upon thermalcompatibility of each constituent layer for structural integrity.

[0013] Additionally, it would desirable to have a laminate webcomprising nonwoven webs and component webs of different materialproperties.

[0014] Additionally, it would be desirable to have a laminate web formedby joining the constituent layers without adhesive.

[0015] Further, it would be desirable to have an apertured laminate webhaving visually distinct regions giving a fabric-like or knit-like lookand feel.

BRIEF SUMMARY OF THE INVENTION

[0016] A laminate web and several uses of the laminate web aredisclosed. The laminate web comprises a first web, a second web joinedto the first web at a plurality of discrete bond sites; and a thirdmaterial disposed between at least a portion of the first and secondwebs. The bond site defines an elongated melt weakened region with anaspect ratio of at least about 2. The bond site has a longitudinal axisoriented in a first direction and a transverse axis oriented in a seconddirection orthogonal to the first direction. The third material may beapertured in regions adjacent the bond sites, such that the first andsecond nonwoven webs are joined through the apertures.

[0017] In one embodiment an apertured laminate web is disclosed, havinga first extensible web having a first elongation to break, and a secondextensible web joined to the first extensible web at a plurality of bondsites, the second extensible web having a second elongation to break. Athird web material is disposed between the first and second nonwovens,the third web material having a third elongation to break which is lessthan both of the first or second elongations to break.

[0018] In a further embodiment, an apertured laminate web is disclose,having first and second extensible webs being joined at a plurality ofdiscrete bond sites and a third material disposed between the first andsecond nonwoven webs. The first and second nonwoven webs are in fluidcommunication via the apertures and have distinct regions beingdifferentiated by at least one property selected from the groupconsisting of basis weight, fiber orientation, thickness, and density.

[0019] The laminate webs of the present invention are suitable for avariety of uses. Such uses include flexible carrying implements, medicalapplications, kitchen or bathroom implements, decorative coverings, homeaccent items, pet industry articles, fabrics, fabric backings, ediblematerials, bedding applications, absorbent food pads, clean room wipes,tack cloths, and many other uses.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] While the specification concludes with claims pointing out anddistinctly claiming the present invention, it is believed the same willbe better understood by the following drawings taken in conjunction withthe accompanying specification wherein like components are given thesame reference number.

[0021]FIG. 1 is a perspective of one embodiment of a laminate web of thepresent invention.

[0022]FIG. 2 is a cross-sectional view of a portion of the laminate webshown in FIG. 1.

[0023]FIG. 3 is a magnified detail view of one bond site of a laminateweb of the present invention.

[0024]FIG. 4 is a top plan view of another embodiment of the laminateweb of the present invention.

[0025]FIG. 5 is a cross-sectional view of a portion of the laminate webshown in FIG. 4.

[0026]FIG. 6 is a top plan view of another embodiment of the laminateweb of the present invention.

[0027]FIG. 7 is a cross-sectional view of a portion of the laminate webshown in FIG. 6.

[0028]FIG. 8 is a photomicrograph of one embodiment of a laminate web ofthe present invention.

[0029]FIG. 9 is a schematic representation of a process for making alaminate web of the present invention.

[0030]FIG. 10 is a perspective view of a melt bond calendaringapparatus.

[0031]FIG. 11 is a schematic representation of a pattern for theprotuberances of the calendaring roll.

[0032]FIG. 12 is a perspective view of an apparatus for stretching alaminate of the present invention to form apertures therein.

[0033]FIG. 13 is a cross-sectional view of a portion of the matingportions of the apparatus shown in FIG. 12.

[0034]FIG. 14 is a perspective view of an alternative apparatus forstretching a laminate of the present invention in the cross-machinedirection to form apertures therein.

[0035]FIG. 15 is a perspective view of another alternative apparatus forstretching a laminate of the present invention in the machine directionto form apertures therein.

[0036]FIG. 16 is a perspective representation of an apparatus forstretching a laminate of the present invention in both the cross-machineand machine directions to form apertures therein.

[0037]FIG. 17 A-B are cross-sectional photographs of a bond site beforeand after the tensioning step to form an aperture.

DETAILED DESCRIPTION OF THE INVENTION

[0038] As used herein, the term “absorbent article” refers to deviceswhich absorb and contain body exudates, and, more specifically, refersto devices which are placed against or in proximity to the body of thewearer to absorb and contain the various exudates discharged from thebody.

[0039] The term “disposable” is used herein to describe articles whichare not intended to be laundered or otherwise restored or reused (i.e.,they are intended to be discarded after a single use and, preferably, tobe recycled, composted or otherwise disposed of in an environmentallycompatible manner).

[0040] A “unitary” absorbent article refers to absorbent articles whichare formed of separate parts united together to form a coordinatedentity so that they do not require separate manipulative parts like aseparate holder and liner.

[0041] As used herein, the term “nonwoven web” is used in its plainmeaning as understood in the art and refers to a web that has astructure of individual fibers or threads which are interlaid, but notin any regular, repeating manner. Nonwoven webs have been, in the past,formed by a variety of processes, such as, for example, meltblowingprocesses, spunbonding processes and bonded carded web processes.

[0042] As used herein, the term “microfibers”, refers to small diameterfibers having an average diameter not greater than about 100 microns.

[0043] As used herein, the term “meltblown fibers”, refers to fibersformed by extruding a molten thermoplastic material through a pluralityof fine, usually circular, die capillaries as molten threads orfilaments into a high velocity gas (e.g., air) stream which attenuatesthe filaments of molten thermoplastic material to reduce their diameter,which may be to a microfiber diameter. Thereafter, the meltblown fibersare carried by the high velocity gas stream and are deposited on acollecting surface to form a web of randomly dispersed meltblown fibers.

[0044] As used herein, the term “spunbonded fibers”, refers to smalldiameter fibers which are formed by extruding a molten thermoplasticmaterial as filaments from a plurality of fine, usually circular,capillaries of a spinneret with the diameter of the extruded filamentsthen being rapidly reduced by drawing.

[0045] As used herein, the term “unitary web” refers to a layered webcomprising two or more webs of material, including nonwoven webs, thatare sufficiently joined, such as by thermal bonding means, to behandled, processed, or otherwise utilized, as a single web.

[0046] As used herein, “laminate” and “composite” when used to describewebs of the present invention, are synonymous. Both refer to a webstructure comprising at least two webs joined in a face-to-facerelationship to form a multiple-layer unitary web.

[0047] As used herein, the term “polymer” generally includes, but is notlimited to, homopolymers, copolymers, such as, for example, block,graft, random and alternating copolymers, terpolymers, etc., and blendsand modifications thereof. Furthermore, unless otherwise specificallylimited, the term “polymer” shall include all possible geometricalconfigurations of the material. These configurations include, but arenot limited to, isotactic, syndiaotactic and random symmetries.

[0048] As used herein, the term “elastic” refers to any material which,upon application of a biasing force, is stretchable, that is,elongatable, at least about 60 percent (i.e., to a stretched, biasedlength, which is at least about 160 percent of its relaxed unbiasedlength), and which, will recover at least 55 percent of its elongationupon release of the stretching, elongation force. A hypothetical examplewould be a one (1) inch sample of a material which is elongatable to atleast 1.60 inches, and which, upon being elongated to 1.60 inches andreleased, will recover to a length of not more than 1.27 inches.

[0049] Many elastic materials may be elongated by more than 60 percent(i.e., much more than 160 percent of their relaxed length), for example,elongated 100 percent or more, and many of these materials will recoverto substantially their initial relaxed length, for example, to within105 percent of their initial relaxed length, upon release of the stretchforce. Such materials are denoted herein by the term “highly elastic”which refers to any material which upon application of a biasing force,is stretchable, that is, elongatable, at least about 200 percent (i.e.,to a stretched, biased length, which is at least about 300 percent ofits relaxed unbiased length), and which, will to within 105 percent oftheir initial relaxed length, upon release of the stretch force.Therefore, highly elastic materials are generally also elastic, but notall elastic materials are highly elastic.

[0050] As used herein, the term “nonelastic” refers to any materialwhich does not fall within the definition of “elastic” above.

[0051] As used herein, the term “extensible” refers to any materialwhich, upon application of a biasing force, is elongatable, at leastabout 25 percent without experiencing catastrophic failure. Catastrophicfailure includes substantial tearing, fracturing, rupturing, or otherfailure in tension such that, if tested in a standard tensile tester,the failure would result in a sudden significant reduction in tensileforce. As used herein, the term “highly extensible” refers to anymaterial which, upon application of a biasing force, is elongatable, atleast about 100 percent without experiencing catastrophic failure.

[0052] The Laminate Web

[0053] The laminate web 10 of the present invention comprises at leastthree layers or plies, disposed in a layered, face-to-face relationship,as shown in FIG. 1. The layers should be sufficiently thin to beprocessible as described herein, but no actual thickness (i.e., caliper)is considered limiting. A first outer layer 20, is preferably thermallybondable, and is preferably a nonwoven web comprising a sufficientquantity of thermoplastic material, the web having a predeterminedextensibility and elongation to break. By “sufficient quantity” is meanta quantity of thermoplastic material adequate to enable enough thermalbonding upon application of heat and/or pressure to produce a unitaryweb. A second outer layer, 40, is preferably the same material as firstouter layer 20, but may be a different material, also being thermallybondable and having a predetermined extensibility and elongation tobreak. At least one third central layer 30 is disposed between the twoouter layers. The laminate web 10 is processed by joining means, such asby ultrasonic welding, or thermal calendaring as described below toprovide a plurality of melt bond sites 50 that serve to couple the outerlayers 20 and 40, and, in some embodiments, portions of central layer30, thereby forming the constituent layers into a unitary web. Whenjoined together, the two outer layers form an interior region betweenthem. The interior region is the space between the outer layerssurrounding the bond sites 50. In a preferred embodiment, the thirdcentral layer 30 substantially fills the interior region, the thirdcentral layer 30 being apertured coincident the bond sites 50.

[0054] While the laminate web 10 is disclosed primarily in the contextof nonwoven webs and composites, in principle the laminate web 10 can bemade out of any web materials that meet the requirements, (e.g., meltproperties, extensibility) as disclosed herein. For example, the outerlayers 20 and 40 can be thermoplastic films, micro-porous films,apertured films, woven fabrics, and the like. Central layer 30 can bepaper, including tissue paper; metal, including metal foil; othernon-thermoplastic web material, woven fabric, and the like. In general,it is required that outer layer materials be flexible enough to beprocessed as described herein. However, central layer can be a brittle,relatively stiff material, as long at it also can be processed asdescribed herein, albeit possibly becoming fractured, broken, orotherwise broken up in the process. One of the unexpected advantages ofthe present invention, therefore, is the discovery that novel webproperties can be exhibited by the choice of central layer 30 disposedbetween the two outer layers.

[0055] Non-Apertured Embodiment

[0056] In one embodiment, as shown in cross-section in FIG. 2, centrallayer 30 can be apertured, without aperturing the two outer layers toprovide a three-layer laminate characterized by the laminate web 10 (asa whole) being un-apertured, while the central layer 30 is apertured.Importantly, the web of the present invention can be made by the methodof the present invention without requiring registration of the layers toensure bonding of the outer layers through the apertures of the centrallayer(s). One way of describing a preferred embodiment of a web 10 asdescribed above, is that the unitary web 10, when viewed orthogonally bythe un-aided human eye from a distance of approximately 50 cm, exhibitsno apertures or perforations through the entire laminate, but bond sites50 are nevertheless visible.

[0057] The laminate web 10 is further characterized in that the joiningof the three plies into a unitary web can be achieved in the absence ofadhesive. That is, in certain preferred embodiments no adhesive isrequired to bond the plies together; joining is achieved by the input ofenergy into the constituent layers, such as by thermal melt bonding ofthe two outer layers together at the melt bond sites 50. In otherembodiments, the energy input can be via ultrasonic bonding.Accordingly, a significant benefit of the present invention is theprovision of a laminate web, that is a unitary web, formed without theuse of adhesives. Not only does this simplify processing and lower thecost of the laminate web, when certain materials such as nonwoven websare used, it results in a more flexible, softer web.

[0058] As shown in FIG. 2, central layer 30 is chosen such that when theconstituent web layers of laminate web 10 are processed by the method ofthe present invention, portions of central layer 30 in the region of themelt bond sites 50 separate to permit the first outer layer 20 to meltbond directly to the second outer layer 40 at the interface of the twomaterials 52 at melt bond sites 50. Thus, apertures in the central layer30 are formed in the lamination step by displacement, just prior to thebonding of the outer layers as detailed by the method of the presentinvention below. In this manner, central layer 30 can be provided as anunapertured web, avoiding complex registration steps to align aperturesin registry with bond sites when laminated. Further, central layer 30need not be thermally compatible with outer layers 20 and 40. Centrallayer need not be a thermoplastic material, and need not even have amelting point. It simply needs to be displaceable by the forces exertedby the processing equipment as detailed below. Therefore, one way ofdescribing the laminate web of the present invention is to distinguishthe central layer as being a material differentiated from the materialsof the first or second layers by at least one material property selectedfrom thermal properties, elongation properties, elastic properties, orconductive properties. By “thermal properties” is meant primarilythermal melt properties, such that the central layer has no meltingpoint, or if it has a melting point, it is preferably at least about 10degrees Centigrade higher, more preferably about 20 degrees Centigradehigher than either outer layer, and can be 100 degrees Centigrade higherthan either outer layer. By “elongation properties” is meant that intension, the material of the central layer exhibits an elongation tobreak that is at least 10% less than either outer layer, more preferably50% less than either outer layer, and can be greater than 100% less thaneither outer layer. Thus, the central layer can be extensible, whileeither outer layer can be highly extensible. By “elastic properties” ismeant that the central layer can be, for example, elastic, while eitherouter layer can be highly elastic, as defined herein. Or the centrallayer can be non-elastic, and the outer layers elastic or highlyelastic. By “conductive properties” as used herein is meant electricallyconductivity, such that the central layer can have an electricalconductivity that is 10 times, and more preferably 100 or more times asgreat as the outer layers. Conductive properties may be facilitated bythe central layer being a metallic foil, or by being a conductivepolymer, including a conductive nonwoven web.

[0059] Another advantage of the method of the present invention is that,in some embodiments, e.g., for solid core central layer 30 materials(i.e., a continuous sheet, that is, not having substantial apertures,gaps, or other voids), it results in a unitary web having an aperturedcentral layer 30 in full, intimate contact with the outer layers 20, and40. By “full” and “intimate” is meant that central layer 30 fills allthe unbonded regions between outer layers 20 and 40 such that outerlayers 20 and 40 do not contact except at the bond sites 50. Of course,it is recognized that many materials of interest have significant aircontent, and filling “all” the unbonded region between outer layers 20and 40 is not meant to imply that all air content is removed.

[0060] Central layer 30 can be involved, or participate, in the bondingbetween outer layers 20 and 40. By “involved” is meant that the centrallayer can, to some extent, be in intimate contact with, and possiblypartially merged with, one or both immediate outer layers. Theinvolvement may be due to actual melt bonding about the perimeter ofbond site 50 (e.g., for thermoplastic central layers 30), or it may bedue to mechanical interaction, such as by entanglement (e.g., forcellulosic fibrous central layer 30 between fibrous nonwoven layers),also about the perimeter of bond site 50. For example, FIG. 17-A showsin cross-section a unitary web comprising two outer nonwoven layers anda cellulosic tissue paper central layer. As can be seen, thelighter-colored central layer, due to the process of being “squeezed”apart, is intimately involved with the two outer layers at the bondsite.

[0061] Without being bound by theory, it is believed that the process ofthe present invention facilitates such separation of central layer 30 byshearing, cutting, or otherwise fracturing the central layer 30, anddisplacing the material of the central layer 30 sufficiently to permitthermal bonding of the two outer layers 20 and 40. Thus, central layer30 must be chosen to have properties that permit such displacement.Therefore, central layer 30 should have one or more of the properties ofrelatively low extensibility, relatively high frangibility, orrelatively high deformability, such that the material of central layer30 can be “squeezed” or otherwise displaced out of the region of thermalbond sites 50. Importantly, it is not required that the central layer 30be melted out of the region of the thermal bond sites. Thus, centrallayer can be elastic, highly elastic, extensible, or highly extensible,depending on the desired end results and purposes of the resultingunitary web.

[0062] Without being bound by theory, it is believed that to accomplishthe displacement of central layer 30 to form apertures therein and tobond the outer layers, the thermal point calendaring described belowshould form thermal bond sites having a narrow width W dimension and ahigh aspect ratio. For example, FIG. 3 shows the melt area of a singlemelt bond site 50 having a narrow width dimension W and a high aspectratio, i.e., the length, L, is much greater than the width, W. Thelength L should be selected to permit adequate bond area while width Wis sufficiently narrow such that the protuberance used to form the bondsite (as described below) can cut, shear, displace, or otherwise piercethe central layer 30 at the region of the bond sites by the methoddescribed below. Width W can be between about 0.003 inches and 0.020inches, but in a preferred embodiment, is between about 0.005 inches and0.010 inches, and may be adjusted depending on the properties of centrallayer 30.

[0063] It is believed that the aspect ratio of melt bond site 50 can beas low as about 2 (i.e., ratio of L/W equals 2/1). It can also bebetween about 2 and 100 or between about 3 and 50 or preferably betweenabout 4 and 30. In one preferred embodiment, the aspect ratio was about10 and in other embodiment about 25. It is believed that the aspectratio of the melt bond sites 50 is limited only by the correspondingaspect ratio of the point bonding protuberances of the calendaringroller(s), as detailed below. The bond site may be described as anelongated melt weakened region with a longitudinal axis oriented in afirst direction and a transverse axis oriented in a second directionorthogonal to the first direction.

[0064] In a preferred embodiment, the longitudinal axis of each bondsite, 1, which corresponds directionally to the length dimension of bondsite 50, is disposed in a regular, repeating pattern oriented generallyparallel to the machine direction, MD as shown in FIG. 1. But thelongitudinal axis of each bond site may be disposed in a regular,repeating pattern oriented in the cross machine direction, or randomlyoriented in a mixture of cross and machine directions. For example, thebond sites 50 can be disposed in a “herringbone” pattern.

[0065] When nonwoven webs are used as constituent layers of laminate 10,an important distinction should be drawn between bond sites 50 whichbond together outer layers 20 and 40 by the method of the presentinvention, and thermal bond sites that may be present in the constituentlayers themselves. For example, nonwoven webs are typically consolidatedby thermal bonding in a regular pattern of discrete spaced apart fusedbonding areas, such as the pattern disclosed in U.S. Pat. No. 3,855,046to Hansen et al., and the patterns shown generally in FIGS. 10 and 11 ofU.S. Pat. No. 5,620,779 to Levy et al. Other films, nonwoven webs, andthe like may have thermal embossments for aesthetic reasons. Therefore,in the unitary web 10 there may be many thermal bond sites, some ofwhich are bond sites 50, and others which are bond sites in the basenonwoven, for example.

[0066] The bond sites of the base nonwoven do not typically have anaspect ratio greater than about 1, so that these bonds do not typicallyform apertures in the constituent layer during the stretching stepdisclosed below. Also, the spacing of such bond sites is typically arepeating pattern of bonded and unbonded area which may or may notprovide for machine direction (MD) columns of bonded area next tocolumns of unbonded area. After forming bond sites 50, however, there isnot likely to be any significant MD columns of unbonded areas; theoverall bond pattern of any constituent nonwoven fabric is a combinationof existing bonded areas and bond sites 50. Together the two sets ofbond sites result in a complex pattern of bond sites that may or may notbe described as columnar, regular, or uniform.

[0067] The resulting web of the present invention, as shown incross-section in FIG. 2, is a laminate web 10 that is itselfunapertured, but the central layer 30 is apertured coincident theregions of the bond sites 50. As stated above, by “unapertured” is meantthat, on the whole, the laminate web 10 is considered unapertured. It isrecognized that the unapertured laminate web 10 of the present inventionmay have localized cut through, or tearing at bond sites 50 due tomaterials and processing variability or post lamination handling.Ideally, such cut through of the entire web is minimized and eliminated.Likewise, it is recognized that in some instances, there may not becomplete displacement of the central layer 30 at all locations of bondsites 50 such that some localized portions of central layer 30 may notbe apertured (and the outer layers not bonded). Nevertheless, thedescription herein is made for the laminate web 50 as a whole, and isnot meant to be limited by aberrations or anomalies due to potentialmaterial or processing variables.

[0068] To produce the webs of the present invention, including asdescribed in FIG. 2, the outer layers should have sufficient elongationto permit the necessary local deformation in the immediate vicinity ofbond sites 50. Thus, the outer layers 20 and 40 can be extensible,highly extensible, elastic, or highly elastic.

[0069] The central layer 30 itself need not be thermally compatible withthe outer layers. The central layer 30 need not even be meltprocessible. It can be, for example, a cellulosic material, such aspaper; a metallic material, such as a metal foil; a woven or knitmaterial, such as cotton or rayon blends; or a thermoset material, suchas a polyester or aromatic polyamide film. The central layer 30 can beanother nonwoven having suitable properties for processing into anapertured layer. If central layer 30 has a melting point, it ispreferably at least about 10 degrees Centigrade higher, more preferablyabout 20 degrees Centigrade higher than the outer layers. In certainembodiments, for example a metal foil central layer 30 betweenthermoplastic nonwoven outer layers, the central layer can have amelting point at least 100 degrees Centigrade higher than the outerlayers. However, central layer 30 need not have a melting point, and maysimply experience softening at the calendaring temperatures required tobond the laminate. In certain central layer materials, such as metalfoils, there may not be any softening due to thermal processing of theweb.

[0070] The wide range of possible central layer materials permits asurprising variety of structures of the present invention, each havingbeneficial application in a wide assortment of end uses. For example,when outer layers of nonwoven material are used with a central layer ofmetal foil, the resulting laminate is a flexible, soft, formable,conductive web that is relatively quiet when folded, crumpled orotherwise deformed. Such a material can be used in applicationsrequiring electrical shielding, for example. When a central layer oftissue paper is used, the resulting laminate is a soft, bulky, absorbentweb. Such a laminate is suitable for use as a wiping implement, forexample. Further, since the laminate web 10 is formed without the use ofthermoplastic adhesives, durable, garment-like properties can beobtained. Such laminates can be laundered a number of times beforesuffering unacceptable wear.

[0071] By way of example, laminate web 10 can be a conductive fabriccomprising relatively non-conductive thermoplastic outer layers 20 and40 and a relatively conductive central layer 30. The outer layers can benon-woven webs for a low cost, soft, breathable conductive fabric. Thecentral layer can be a metal foil, such as a copper foil or an aluminumfoil. The central layer can also be a conductive polymer, a non-foilconductive fabric, or a composite conductive material. In general, as aconductive fabric embodiment, the outer layers should serve to insulatethe conductive central layer(s). In a preferred three-layer embodimentthe outer layers each have a first electrical resistance and the centrallayer has a second electrical resistance which is at least one-tenth thefirst electrical resistance, more preferably one-hundredth (i.e., thecentral layer is 10 times, preferably 100 times as conductive as theouter layers).

[0072] A conductive laminate web 10 can find use as a sheet ofconductive material for signal propagation. It can also find use as ashielding material. In particular, the aspect ratio of the bond sites 50can be predetermined for particular shielding characteristics. Byaltering the length, width, and orientation of the bond sites 50 certainwave propagation of electromagnetic waves can be altered or stopped. Forexample, the bond sites 50, which represent penetration of theconductive central layer, can be designed to be effective in filteringcertain wavelengths of electromagnetic radiation. In addition to theelectrical characteristics of such a web, the laminate web 10 can be,and preferably is, very flexible and formable, such that the conductiveor shielding benefits can be applied in a non-planar fashion. Forexample, sensitive electronic equipment can be wrapped with a fabricshield.

[0073] A further benefit of the present invention is the capability tocombine both thermoplastic and non-thermoplastic materials without anyadhesives, to provide fabric-like composites having unique physicalproperties. For example, a material having high tensile strength andresistance to tear can include as a central layer 30 TYVEK®, availablefrom DuPont, Wilmington Del., USA. TYVEK®, and equivalent or similarmaterials under other tradenames, is an extremely strong but breathablepolyolefin nonwoven, commonly used as a house-wrap layer. However, it isnot soft and clothlike, but has the look and feel of a plastic film.When used in a laminate web 10 of the present invention, for examplewith nonwoven outer layers, the laminate web exhibits the softness of anonwoven with the strength of the TYVEK® layer. Again, this laminate canbe, and is preferably, made without the use of adhesives to bind the webinto a unitary web.

[0074] Further, relatively strong materials such as TYVEK® can becombined with additional central layers 30 to make laminate webs 10having a variety of physical properties. For example, a laminate webcomprising a TYVEK® layer can also comprise an absorbent layer, such alayer of absorbent tissue paper, such as BOUNTY® paper towel, availablefrom The Procter & Gamble Co., Cincinnati Ohio, USA and one or moreouter layers of polyethylene nonwoven (e.g. Corolind, available fromBBA, Simpsonville, S.C., USA). Such a composite formed according to themethod of the present invention can be transformed into a highlytextile-like material, exhibiting the unusual combined properties ofrelatively high absorbency (from the BOUNTY® paper towel layer(s)), andrelatively high strength (from the TYVEK® layer(s)).

[0075] Apertured Embodiments

[0076] A further benefit of the present invention is obtained when thenon-apertured thermally bonded laminate web described above is stretchedor extended in a direction generally orthogonal to the longitudinalaxis, 1, of melt bond sites 50. The melt bonding at the melt bond sites50 tends to make localized weakened portions of the web at the bondsites. Thus, as portions of the web 10 are extended in a directiongenerally orthogonal to the longitudinal axis 1 of bond sites 50, thematerial at the bond site fails in tension and an aperture is formed.The relatively high aspect ratio of melt bond sites 50, permits arelatively large aperture to be formed upon sufficient extension. Whenthe laminate web 10 is uniformly tensioned, the result is a regularpattern of a plurality of apertures 60 corresponding to the pattern ofmelt bond sites 50.

[0077]FIG. 4 shows a partially cut-away representation of an aperturedlaminate of the present invention. As shown, the partial cut-awaypermits each layer or ply to be viewed in a plan view. The laminate web10 shown in FIG. 4 is produced after the thermally bonded laminate isstretched in a direction orthogonal to the longitudinal axis of the meltbond sites, in this case, in the cross-machine direction, CD withsufficient elongation in the direction of extension to cause aperturesto form. As shown, where formerly were melt bond sites 50, apertures 60are produced as the relatively weak bond sites fail in tension. Also asshown, central layer 30 can remain generally uniformly distributedwithin laminate 10, depending on the material properties of centrallayer 30. For example, if central layer 30 is more extensible than outerlayers 20 or 40, then it simply extends, either elastically or byplastic deformation, but remains generally uniformly distributed in theunapertured regions of web 10. For example, if a thermoplastic film isutilized as the central layer 30, it extends, either extensibly orelastically (depending on the type of film), but can remain generallyuniform, for example, in density or basis weight.

[0078] When apertures 60 are formed, the thermally bonded portions ofouter layers 20 and 40 remain primarily on the portions of the apertureperimeters corresponding to the length dimension of bond sites 50.Therefore, each aperture 60 does not have a perimeter of thermallybonded material, but only portions remain bonded, represented as 62 inFIG. 4. One beneficial property of such a laminate web is that onceapertured, fluid communication with the central layer is facilitated.Thus, an absorbent central layer 30 can be used between two relativelynon-absorbent outer layers, and the laminate 10 could be an absorptivewiper with a relatively dry to the touch outer surface.

[0079] To the extent that central layer 30 is involved, or participates,in any bonding between outer layers 20 and 40, it also participates inthe remnant of bonded portions 62, as shown in FIG. 4. The involvementmay be due to some degree of actual melt bonding about the perimeter ofbond site 50 (e.g., for thermoplastic central layers 30), or it may bedue to mechanical interaction, such as by entanglement (e.g., forcellulosic fibrous central layer 30 between fibrous nonwoven layers).FIG. 5 is a schematic representation of the cross-section denoted inFIG. 4. As shown, apertures 60 form when the laminate web is elongatedin the direction T.

[0080] Another benefit of the present invention is obtained when thelaminate is extended as described with reference to FIG. 4, but thecentral layer 30 is chosen to have an elongation to break less thaneither of the two outer layers, and less than the actual magnitude ofextension. Thus, upon extension of the laminate web generally orthogonalto the longitudinal axis, 1, sufficient to form apertures in outerlayers 20 and 40 (and thus the entire laminate web 10) central layer 30fails in tension. Therefore, central layer 30 fractures (i.e., fails intension) upon sufficient extension, such that after extension centrallayer 30 is no longer uniformly distributed over the non-aperturedregions of the laminate web 10.

[0081] An example of one embodiment of a unitary web having a centrallayer having an elongation to break less than either of the two outerlayers, and less than the actual magnitude of extension, is shownpartially cut-away in FIG. 5. The partial cut-away permits each layer orply to be viewed in a plan view. As shown, after extension, centrallayer 30 becomes fragmented, forming discontinuous regions of thecentral layer material. These discontinuous regions may be relativelyuniformly distributed, such as in rows as shown in FIG. 5, or may berelatively randomly distributed, depending on the pattern of melt bondsites 50, the physical properties of central layer 30, and the method ofextension employed.

[0082] One example of a web 10 having a structure similar to that shownin FIG. 5 is a web having outer layers of relatively extensiblenonwovens, with a central layer of relatively low extensibility tissuepaper. Such a laminate would be an apertured laminate web having anabsorbent central core, wherein the absorbent core material is in fluidcommunication with regions exterior to the laminate web. That is, forexample, if such a laminate web comprised nonwoven outer layers, itcould be used as an absorbent wiper. Fluids could thus be absorbed viathe apertures, the perimeter of which can be open at portions whichprovide fluid communication to the absorbent central core. If arelatively hydrophobic nonwoven web is used for the outer layers, such awiper could exhibit dry-to-the-touch properties along with highabsorbency.

[0083] One example of a web 10 having a structure similar to that shownin FIG. 5 is a web having outer layers of relatively extensiblenonwovens, with a central layer of relatively low extensibility tissuepaper. One particularly interesting structure incorporates a highlyhydrophobic outer layer combined with a highly absorbent central layer.A suitable hydrophobic material is described in U.S. Pat. No. 3,354,022Dettre et al. Such a material has a water repellent surface having anintrinsic advancing water contact angle of more than 90 degrees and anintrinsic receding water contact angle of at least 75 degrees. Such amaterial exhibits extremely hydrophobic properties, similar to theeffect known to exist on leaves from the Lotus plant. When such amaterial is combined with an absorbent central layer, such as a BOUNTY®paper towel tissue layer, the resulting composite can be highlyabsorbent while retaining a very clean and dry outer surface. The basisweight and porosity of the outer layer can be varied to achievedifferent degrees of absorbent performance. In one embodiment thelaminate could also be post-laminated to a fluid-impervious backinglayer to form an absorbent fluid barrier. The fluid-impervious backinglayer could be a flexible polymeric film for use such absorbent articlesas sanitary napkins, diapers, place mats, floor mats, protective covers,and the like.

[0084] One surprising beneficial characteristic of the laminate webstructure of the present invention described with reference to FIG. 6 isthe presence of distinct regions in the nonapertured portion of the webbeing differentiated by at least one property selected from the groupconsisting of basis weight, thickness, or density. As shown in thecross-section of FIG. 7, several such regions can be differentiated. Ina preferred embodiment, the regions are visually distinct, giving thelaminate an aesthetically pleasing look and feel. The regions may alsogive the laminate a garment-like or knit-like texture and hand.

[0085] With reference to FIG. 7, several structurally distinct regionscan be identified in the cross-section shown. The region denoted 64corresponds to the aperture 60. In the nonapertured area of the web, aregion 66 is a relatively high basis weight region comprising centrallayer 30. Region 68 represents the portion of the laminate web in whichcentral layer 30 has fractured and separated, i.e., is no longer fullypresent, forming a relatively low basis weight region of web 10. Ingeneral, the higher basis weight regions will also be correspondinglyhigher density regions, but need not be so. For example, apost-extension embossing process can be applied to web 10 to formregions of multiple densities in addition to the regions of multiplebasis weight. For either the high basis weight regions or the highdensity regions, often the differences can be discernible by simplyrubbing the laminate web between the fingers.

[0086] In general, for a laminate web 10 having generally parallel rowsof melt bond sites 50 extending in the machine direction MD, whichcorrespondingly form generally parallel rows of apertures when extended,and having a central layer with a lower elongation to break than theouter layers, the resulting extended, apertured laminate web 10 ischaracterized by generally low basis weight, low density regions betweenthe apertures in the machine direction, MD, e.g., region 68 in FIGS. 6and 7. Likewise, such a laminate web 10 is characterized by relativelyhigh basis weight, high density regions between adjacent rows ofapertures in the cross-machine direction, CD, e.g., region 66 in FIG. 7.By choice of central layer material 30 and possibly post laminatingoperations, e.g., an embossing process, the thickness of the laminateweb can likewise be varied, the thicker regions generally correspondingto the higher density regions.

[0087] On particularly useful embodiment of a laminate web as describedwith reference to FIG. 7, is a conductive fabric for signal transmissionvia a plurality of closely-spaced, parallel signal conductors. Forexample, if a conductive metal foil is used as central layer 30, uponsufficient extension in the CD by the incremental stretching operationdescribed below, the metal foil fractures into a plurality of discreteconductive ribbons corresponding to the high basis weight region 66 ofFIG. 7. Outer layers 20 and 40 are preferably chosen for theirinsulating properties, and are, therefore, preferably thermoplasticpolymeric material. For high-speed transmission of electrical signals, alow-dielectric material, such as polytetrafluoroethylene (PTFE), andpreferably expanded PTFE (e.g., GORE-TEX® available from W. L. Gore andAssociates, Newark, Del., USA) can be used as the insulating outerlayers. Additional outer layers can be added (e.g., post laminateformation), including additional conductive layers to form a shieldedribbon cable. Another embodiment of a laminate web of the presentinvention utilizing nonwoven webs as the outer layers is characterizedby distinct regions differentiated by fiber orientation. Differentialfiber orientation can be achieved by providing for localized regionswithin the web that experience greater extension than other regions. Forexample, by locally straining the web 10 to a greater degree in theregions corresponding to regions 68 in FIG. 6, regions of significantfiber reorientation are formed. Such localized straining is possible bythe method of the present invention detailed below.

[0088]FIG. 8 is a photomicrograph showing in magnified detail a web ofthe present invention comprising nonwoven outer layers which has beenextended to form apertures, and locally extended to produce regions 68of fiber reorientation. As can be seen in FIG. 8, by locally extendingportions of the web to a greater extent than others, the aperturesformed thereby can be of different sizes. Thus, the region denotedgenerally as 70 in FIG. 8 has undergone more strain (i.e., localextension) than the region denoted by 72. Thus, the apertures in region70 are larger than those in region 72, and the basis weight of thenonwoven web material in region 72 is less than the basis weight of thenonwoven web in region 70. In addition to the difference in basis weightdue to localized strain differentials, the laminate web of the presentinvention can also exhibit distinct regions 68 of fiber reorientation.In these regions, the fibers have been reoriented from a generallyrandom orientation to a predominant orientation in the direction ofextension.

[0089] To make a web 10 as shown in FIG. 6, central layer 30 can be anyof a great number of dissimilar materials. For example, if outer layers20 and 40 are nonwoven webs having a relatively high elongation tobreak, central layer 30 can be paper, tissue paper, thermoplastic film,metal foil, closed or open cell foam, or any other material that has arelatively low elongation to break compared to the two outer layers. Theouter layer materials may themselves be dissimilar, with the onlyconstraint being that the central layer be relatively less extensible inthe direction of extension to form apertures.

[0090] Additionally, more than one central layer 30 can be used withbeneficial results. For example, a structure comprising a cellulosictissue central web and a polymeric film central web between two nonwovenwebs can produce an absorptive wiping article with one side beingrelatively more absorptive than the other. If the film layer is athree-dimensional formed film, the film side can provide added textureto the laminate which is beneficial in many wiping applications.Macroscopically-expanded, three-dimensional formed films suitable foruse in the present invention include those described incommonly-assigned U.S. Pat. No. 3,929,135 issued to Thompson on Dec. 30,1975, and U.S. Pat. No. 4,342,314 issued to Radel et al. on Aug. 3,1982, both patents hereby incorporated herein by reference.

[0091] The (or “a”) central layer can also be elastomeric, and can be anelastomeric macroscopically-expanded, vacuum-formed, three-dimensionalformed film, such as described in commonly-assigned U.S. Ser. No.08/816,106, entitled “Tear Resistant Porous Extensible Web” filed byCurro et al. on Mar. 14, 1997, and hereby incorporated herein byreference. Further, the (or “a”) central layer can be athree-dimensional formed film having micro-apertures such as describedin commonly-assigned U.S. Pat. Nos. 4,629,643 issued to Curro et al. onDec. 16, 1986, and 4,609,518, issued to Curro et al. on Sep. 2, 1986,both of which are hereby incorporated herein by reference.

[0092] The (or “a”) central layer can be a web material having astrainable network as disclosed in U.S. Pat. No. 5,518,801 issued toChappell et al. on May 21, 1996, and hereby incorporated herein byreference. Such a web can be a structural elastic-like film (SELF) web,formed by, for example, embossing by mating plates or rolls.

[0093] The (or “a”) central layer can be an absorbent open cell foam webmaterial. Particularly suitable absorbent foams for high performanceabsorbent articles such as diapers have been made from High InternalPhase Emulsions (hereafter referred to as “HIPE”). See, for example,U.S. Pat. No. 5,260,345 (DesMarais et al), issued Nov. 9, 1993 and U.S.Pat. No. 5,268,224 (DesMarais et al), issued Dec. 7, 1993, herebyincorporated herein by reference. These absorbent HIPE foams providedesirable fluid handling properties, including: (a) relatively goodwicking and fluid distribution characteristics to transport the imbibedurine or other body fluid away from the initial impingement zone andinto other regions of the foam structure to allow for subsequent gushesof fluid to be accommodated; and (b) a relatively high storage capacitywith a relatively high fluid capacity under load, i.e. under compressiveforces.

[0094] The central layer 30 may comprise absorbent gelling materials.For example, supersorbers or hydrogel materials may provide for superiorabsorbency when the laminate web of the present invention is used as anabsorbent wipe or an absorbent core in a disposable absorbent article.By “hydrogel” as used herein is meant an inorganic or organic compoundcapable of absorbing aqueous fluids and retaining them under moderatepressures. For good results the hydrogels should be water insoluble.Examples are inorganic materials such as silica gels and organiccompounds such as cross-linked polymers. Cross-linking may be bycovalent, ionic, vander Waals, or hydrogen bonding. Examples of polymersinclude polyacrylamides, polyvinyl alcohol, ethylene maleic anhydridecopolymers, polyvinyl ethers, hydroxypropyl cellulose, carboxymethylcellulose, polyvinyl pyridine and the like.

[0095] One benefit of the laminate of the present invention is theability to make a laminate structure of dissimilar materials without theuse of adhesive for joining. Because the central layer of the laminateweb 10 is penetrated by the protuberances of the calendaring roll atmelt bond sites, it can comprise non-thermally-bondable materials. Theplurality of melt bond sites 50 are sufficient to keep the componentwebs together in the laminate web, so that the laminate web behaves as aunitary web for processing integrity and use, without unwanteddelamination. However, in some embodiments, and for certain materials,it may be beneficial to apply adhesive between at least two of theconstituent layers.

[0096] The laminate web of the present invention, being bonded by aplurality of relatively closely spaced thermal bond sites (without theuse of thermoplastic adhesives) can be beneficially used for durablearticles. For example, a laminate web of the present inventioncomprising nonwoven web outer layers and having a clothlike feel andappearance, can be used in durable garments. Certain embodiments of thelaminate web of the present invention can survive repeated washing anddrying in household washing and drying equipment, depending on thecomponent webs of the laminate, and the level of thermal bonding. Due tothe knit-like or fabric-like look and feel of certain embodiments of thepresent invention, such durability can result in durable garmentcomponents such as interliners and the like. Alternatively, a wovenfabric can comprise the outer layers to form a durable article.

METHOD OF MAKING

[0097] Referring to FIG. 9 there is schematically illustrated at 100 aprocess making a laminate web of the present invention.

[0098] A first web 120 which can be a relatively extensible web, isunwound from a supply roll 104 and travels in a direction indicated bythe arrows associated therewith as the supply roll 104 rotates in thedirection indicated by the arrows associated therewith. Likewise asecond web 140, which can be a relatively extensible web is unwound fromsupply roll 105. A central layer 130, which can be a relativelyinextensible layer, is likewise drawn from supply roll 107. The threecomponents (or more, if more than one central layer is used) passthrough a nip 106 of the thermal point bond roller arrangement 108formed by rollers 110 and 112.

[0099] In addition to thermoplastic nonwoven materials, either outerlayer can comprise a polymeric film, for example a polyolefinic (e.g.,PP or PE) thin film. If the entire outer layer is not uniformlythermoplastic, at least sufficient amounts to effect melt bonding mustbe thermoplastic. Conjugate fibers, such as bicomponent fibers can beused in the outer layers to facilitate thermal bonding of the outerlayers. Either outer layer can comprise a formed film, such as athree-dimensional formed film having micro-apertures such as describedin commonly-assigned U.S. Pat. Nos. 4,629,643 issued to Curro et al. onDec. 16, 1986, and 4,609,518, issued to Curro et al. on Sep. 2, 1986,both of which are hereby incorporated herein by reference.

[0100] In a preferred embodiment, both outer layers comprise nonwovenmaterials, and may be the identical. The nonwoven material may be formedby known nonwoven extrusion processes, such as, for example, knownmeltblowing processes or known spunbonding processes, and passeddirectly through the nip 106 without first being bonded and/or stored ona supply roll. However, in a preferred embodiment, the nonwoven webs arethemselves thermally point bonded (consolidated) webs commerciallyavailable on supply rolls. The thermal point bonds, which are typicallyin the form of a regular pattern of spaced-apart diamond shaped bondsites, are present in the nonwoven as purchased from a nonwoven vendor,and are to be distinguished in the web of the present invention from thebond sites 50 formed by the method of the present invention.

[0101] The nonwoven web outer layer(s) may be elastic, highly elastic ornonelastic. The nonwoven web may be any melt-fusible web, including aspunbonded web, a meltblown web, or a bonded carded web. If the nonwovenweb is a web of meltblown fibers, it may include meltblown microfibers.The nonwoven web may be made of fiber forming polymers such as, forexample, polyolefins. Exemplary polyolefins include one or more ofpolypropylene, polyethylene, ethylene copolymers, propylene copolymers,and butene copolymers. The nonwoven web can have a basis weight betweenabout 10 to about 60 grams per square meter (gsm), and more preferablyabout 15 to about 30 gsm.

[0102] The nonwoven web outer layers may themselves be a multilayermaterial having, for example, at least one layer of a spunbonded webjoined to at least one layer of a meltblown web, a bonded carded web, orother suitable material. For example, the nonwoven web may be amultilayer web having a first layer of spunbonded polypropylene having abasis weight from about 0.2 to about 8 ounces per square yard, a layerof meltblown polypropylene having a basis weight from about 0.2 to about4 ounces per square yard, and a second layer of spunbonded polypropylenehaving a basis weight from about 0.2 to about 8 ounces per square yard.Alternatively, the nonwoven web may be a single layer of material, suchas, for example, a spunbonded web having a basis weight from about 0.2to about 10 ounces per square yard or a meltblown web having a basisweight from about 0.2 to about 8 ounces per square yard.

[0103] The nonwoven web outer layers may also be a composite made up ofa mixture of two or more different fibers or a mixture of fibers andparticles. Such mixtures may be formed by adding fibers and/orparticulates to the gas stream in which meltblown fibers or spunbondfibers are carried so that an intimate entangled co-mingling of fibersand other materials, e.g., wood pulp, staple fibers and particles occursprior to collection of the fibers.

[0104] Prior to processing by the method of the present invention, thenonwoven web outer cover of fibers can be joined by bonding to form acoherent web structure. Suitable bonding techniques include, but are notlimited to, chemical bonding, thermobonding, such as point calendering,hydroentangling, and needling.

[0105] Referring to FIGS. 9 and 10, the nonwoven thermal bond rollerarrangement 108 preferably comprises a patterned calendar roller 110 anda smooth anvil roller 112. One or both of the patterned calendar roller110 and the smooth anvil roller 112 may be heated and the temperature ofeither roller and the pressure between the two rollers may be adjustedby well known means to provide the desired temperature, if any, andpressure to concurrently displace central layer 30 at melt bond sites,and melt bond the two outer layers together at a plurality of bondsites.

[0106] The patterned calendar roller 110 is configured to have acircular cylindrical surface 114, and a plurality of protuberances orpattern elements 116 which extend outwardly from surface 114. Theprotuberances 116 are disposed in a predetermined pattern with eachprotuberance 116 being configured and disposed to displace central layer30 at melt bond sites, and melt bond the two outer layers together at aplurality of locations. One pattern of protuberances is shownschematically in FIG. 11. As shown, the protuberances 116 have arelatively small width, WP, which can be between about 0.003 inches and0.020 inches, but in a preferred embodiment is about 0.010 inches.Protuberances can have a length, LP, of between about 0.030 inches andabout 0.200 inches, and in a preferred embodiment has a length of about0.100 inches. In a preferred embodiment, the protuberances have anaspect ratio (LP/WP) of 10. The pattern shown is a regular repeatingpattern of staggered protuberances, generally in rows, each separated bya row spacing, RS, of about between about 0.010 inches and about 0.200inches. In a preferred embodiment, row spacing RS is about 0.060 inches.The protuberances can be spaced apart within a row by a protuberancespacing, PS generally equal to the protuberance length, LP. But thespacing and pattern can be varied in any way depending on the endproduct desired.

[0107] As shown in FIG. 10, patterned calendar roller 110 can have arepeating pattern of protuberances 116 which extend about the entirecircumference of surface 114. Alternatively, the protuberances 116 mayextend around a portion, or portions of the circumference of surface114. Likewise, the protuberances 116 may be in a non-repeating pattern,or in a repeating pattern of randomly oriented protuberances. Of course,if randomly oriented, the opening of the resulting bond sites intoapertures will also be somewhat random, depending on the orientation ofthe bond site with respect to the direction of tension, as discussedbelow. For example, if the web is tensioned in the cross-direction (CD)direction only, then the bond sites 50 having a longitudinal axis 1 witha vector component in the machine direction (MD) will open into anaperture, at least to the degree of the magnitude of such a vectorcomponent.

[0108] The protuberances 116 are preferably truncated conical shapeswhich extend radially outwardly from surface 114 and which haverectangular or somewhat elliptical distal end surfaces 117. Although itis not intended to thereby limit the scope of the present invention toprotuberances of only this configuration, it is currently believed thatthe high aspect ratio of the melt bond site 50 is only achievable if theprotuberances likewise have a narrow width and a high aspect ratio atthe distal end surfaces 117, as shown above with reference to FIG. 11.The roller 110 is preferably finished so that all of the end surfaces117 lie in an imaginary right circular cylinder which is coaxial withrespect to the axis of rotation of roller 110.

[0109] The height of the protuberances should be selected according tothe thickness of the laminate being bonded. In general, the heightdimension should be greater than the maximum thickness of the laminateweb during the calendaring process, so that adequate bonding occurs atthe bond sites, and only at the bond sites.

[0110] Anvil roller 112, is preferably a smooth surfaced, right circularcylinder of steel.

[0111] After passing through nip 106, the three (or more) component webs120, 130, and 140 have been formed into unitary laminate web 10. At thispoint in the process the outer layers are thermally bonded to each otherand unapertured, as shown in FIGS. 1 and 2. Central layer(s) 30, fromweb 130, is apertured, having been displaced by protuberances 116 in nip106. Depending on the central layer(s) used, it (they) may or may notparticipate in the bonding about the periphery of the bond sites. Insome instances, particularly for non-thermoplastic, non-fibrousmaterials, central layer may not be involved in the bonding of the outerlayers at all. However, for thermoplastic materials, and fibrousmaterials, some involvement of the central layer(s) is observed.

[0112] The laminate web 10 may be further processed to form apertures inthe whole laminate web (or portions thereof) by extending portions ofthe web in a direction orthogonal to the axis 1 of bond sites 50. Asshown in FIGS. 9 and 10, the axis 1 is generally parallel to the machinedirection MD of the web being processed. Therefore, extension in thecross-direction CD at the bonded portions causes the bond sites 50 torupture and open to form apertures in the web.

[0113] One method for forming apertures across the web is to pass theweb through nip 130 formed by an incremental stretching system 132employing opposed pressure applicators 134 and 136 havingthree-dimensional surfaces which at least to a degree are complementaryto one another. Stretching of the laminate web may be accomplished byother methods known in the art, including tentoring, or even by hand.However, to achieve even strain levels across the web, and especially iflocalized strain differentials are desired, the incremental stretchingsystem disclosed herein is preferred.

[0114] Referring now to FIG. 12, there is shown a fragmentary enlargedview of the incremental stretching system 132 comprising incrementalstretching rollers 134 and 136. The incremental stretching roller 134includes a plurality of teeth 160 and corresponding grooves 161 whichextend about the entire circumference of roller 134. Incrementalstretching roller 136 includes a plurality of teeth 162 and a pluralityof corresponding grooves 163. The teeth 160 on roller 134 intermesh withor engage the grooves 163 on roller 136, while the teeth 162 on roller136 intermesh with or engage the grooves 161 on roller 134. The teeth ofeach roller are generally triangular-shaped, as shown in FIG. 13. Theapex of the teeth may be slightly rounded, if desired for certaineffects in the finished web.

[0115]FIG. 13, shows a portion of the intermeshing of the teeth 160 and162 of rollers 134 and 136, respectively. The term “pitch” as usedherein, refers to the distance between the apexes of adjacent teeth. Thepitch can be between about 0.02 to about 0.30 inches, and is preferablybetween about 0.05 and about 0.15 inches. The height (or depth) of theteeth is measured from the base of the tooth to the apex of the tooth,and is preferably equal for all teeth. The height of the teeth can bebetween about 0.10 inches and 0.90 inches, and is preferably about 0.25inches and 0.50 inches.

[0116] The teeth 160 in one roll can be offset by one-half the pitchfrom the teeth 162 in the other roll, such that the teeth of one roll(e.g., teeth 160) mesh in the valley (e.g., valley 163) between teeth inthe mating roll. The offset permits intermeshing of the two rollers whenthe rollers are “engaged” or in an intermeshing, operative positionrelative to one another. In a preferred embodiment, the teeth of therespective rollers are only partially intermeshing. The degree to whichthe teeth on the opposing rolls intermesh is referred to herein as the“depth of engagement” or “DOE” of the teeth. As shown in FIG. 13, theDOE, E, is the distance between a position designated by plane P1 wherethe apexes of the teeth on the respective rolls are in the same plane(0% engagement) to a position designated by plane P2 where the apexes ofthe teeth of one roll extend inward beyond the plane P1 toward thevalley on the opposing roll. The optimum or effective DOE for particularlaminate webs is dependent upon the height and the pitch of the teethand the materials of the web.

[0117] In other embodiments the teeth of the mating rolls need not bealigned with the valleys of the opposing rolls. That is, the teeth maybe out of phase with the valleys to some degree, ranging from slightlyoffset to greatly offset.

[0118] As the laminate web 10 having melt bonded locations 50 passesthrough the incremental stretching system 132 the laminate web 10 can besubjected to tensioning in the CD or cross-machine direction causing thelaminate web 10 to be extended in the CD direction. Alternatively, oradditionally, the laminate web 10 may be tensioned in the MD (machinedirection). The tensioning force placed on the laminate web 10 can beadjusted (e.g., by adjusting DOE) such that it causes the melt bondedlocations 50 to separate or rupture creating a plurality of apertures 60coincident with the melt bonded locations 50 in the laminate web 10.However, portions of the melt bonds of the laminate web 10 remain, asindicated by portions 62 in FIG. 4, thereby maintaining the laminate webin a coherent, unitary web condition even after the melt bondedlocations rupture.

[0119] After being subjected to the tensioning force applied by theincremental stretching system 132, the laminate web 10 includes aplurality of apertures 60 which are coincident with the melt bondedregions 50 of the laminate web. As mentioned, a portion of thecircumferential edges of apertures 60 include remnants 62 of the meltbonded locations 60. It is believed that the remnants 60 help to resistfurther tearing or delamination of the laminate web. Remnants 62 mayalso contain portions of central layer 30, to the extent that thecentral layer is involved in the bonding.

[0120] Instead of two substantially identical rolls 134 and 136, one orboth rolls can be modified to produce extension and additionalpatterning. For example, one or both rolls can be modified to have cutinto the teeth several evenly-spaced thin channels 246 on the surface ofthe roll, as shown on roll 236 in FIG. 14. In FIG. 14 there is shown anenlarged view of an alternative incremental stretching system 232comprising incremental stretching rollers 234 and 236. The incrementalstretching roller 234 includes a plurality of teeth 260 andcorresponding grooves 261 which extend about the entire circumference ofroller 234. Incremental stretching roller 236 includes a plurality ofteeth 262 and a plurality of corresponding grooves 263. The teeth 260 onroller 234 intermesh with or engage the grooves 263 on roller 236, whilethe teeth 262 on roller 236 intermesh with or engage the grooves 261 onroller 234. The teeth on one or both rollers can have channels 246formed, such as by machining, such that regions of undeformed laminateweb material may remain after stretching. A suitable pattern roll isdescribed in U.S. Pat. No. 5,518,801, issued May 21, 1996, in the nameof Chappell, et al., the disclosure of which is incorporated herein byreference.

[0121] Likewise, the incremental stretching can be by mating rollsoriented as shown in FIG. 15. Such rolls comprise a series of ridges360, 362, and valleys, 361, 363 that run parallel to the axis, A, of theroll, either 334 or 336, respectively. The ridges form a plurality oftriangular-shaped teeth on the surface of the roll. Either or both rollsmay also have a series of spaced-apart channels 346 that are orientedaround the circumference of the cylindrical roll. Rolls as shown areeffective in incrementally stretching a laminate web 10 in the machinedirection, MD if the axis I of bond sites 50 is oriented generallyparallel to the cross-machine, CD direction of the web as its beingprocessed.

[0122] In one embodiment, the method of the present invention cancomprise both CD and MD incremental stretching. As shown in FIG. 16, twopairs of incremental stretching rolls can be used in line, such that onepair (232, which, as shown in FIG. 16 includes a series of spaced-apartchannels 246) performs CD stretching, and another pair, 332 performs MDstretching. By this method many interesting fabric-like textures can bemade. The resulting hand and visual appearance make such fabric-likewebs ideal for use in articles benefiting from a fabric-like look andfeel. For example, if a central layer 30 comprises a material havingless elongation to break than either outer layer, and is stretched tofailure in both the CD and MD directions by the method described herein,the resulting laminate web 10 exhibits “islands” of central layermaterial. The islands are discrete, non-continuous portions of centrallayer, and give the laminate web 10 a decidedly fabric-like look andfeel. In this manner, if a metal foil is used as a central layer 30between two relatively translucent materials, such as low basis weightnonwovens, the resulting laminate web 10 resembles a sequined fabric.

[0123] The use of rather brittle, or relatively still materials can beused as a central layer 30 with beneficial results when the laminate webis incrementally stretched as described herein. For example, thinceramic materials having a relatively high stiffness can be used ascentral layer 30 in a laminate web 10 that is relatively highly flexiblein at least one direction, depending on the direction of stretch.Therefore, if the web is incrementally stretched in the CD direction,the laminate web will be flexible about an axis parallel with the MDdirection, and vice-versa. If the web is incrementally stretched in bothdirections, then the resulting laminate web 10 will be relatively highlyflexible about two axes, and, depending on the size of the discrete“islands” of central layer produced, approaches the overall flexibilityof the two outer layers.

EXAMPLES

[0124] The following examples are shown in Table 1 as exemplary of theclaimed invention. Because the choice of outer and inner layers andcombinations is virtually infinite, the examples shown are meant to beillustrative of possible structures, and are not meant to be limiting toany particular material or structure. In particular, the examples shownare limited to currently preferred structures comprising nonwoven websas the outer layers.

[0125] In Table 1 various combinations of materials are shown. Thelayers are numbered in order of structural proximity from one outerlayer to the other. Therefore, layer 1 is always an outer layer, and thelast numbered layer is likewise an outer layer.

[0126] For all the samples shown, the calendaring line speed was 100feet per minute, but the line speed is not considered critical to theoperation of the method. The calendaring pressure was 700 psig for allthe samples, but the pressure can be varied as desired as long asbonding is achieved between the outer layers.

[0127] To form apertured embodiments of the samples below, the thermallybonded laminate was processed by the incremental stretching process asdescribed above with reference to FIG. 12. For these samples a “Pitch”and depth of engagement (“DOE”) are shown.

[0128] Clopay PE films were obtained from Clopay, Cincinnati, Ohio.These thin (about 0.001″ thick) films are a soft and deformablepolyethylene type, often used as fluid barrier materials for absorbentproducts.

[0129] Tredegar elastomeric formed films were obtained from TredegarFilm Products, Terre Haute, Ind. By “form ed film” is meant amacroscopically-expanded three-dimensional plastic web comprising acontinuum of capillary networks originating in and extending from onesurface of the web and terminating in the form of apertures in theopposite surface thereof. Such a formed film is disclosed in commonlyassigned U.S. Pat. No. 4,342,314 issued to Radel et al. on Aug. 3, 1982.Elastomeric formed films are an 5 improvement in the aforementionedRadel et al. web as disclosed in the above-mentioned commonly assigned,copending U.S. patent application Ser. No. 08/816,106 entitled TearResistant Porous Extensible Web, filed Mar. 14, 1997 in the name ofCurro et al. Curro '106 discloses elasticized polymeric webs generallyin accordance with the aforementioned Radel et al. patent that may beproduced from elastomeric materials known in the art, and may belaminates of polymeric materials. Laminates of this type can be preparedby coextrusion of elastomeric materials and less elastic skin layers andmay be used in the body hugging portions of absorbent garments, such asthe waistband portions and leg cuffs.

[0130] High internal phase emulsion open cell foam materials can be madegenerally in accordance with the teachings of the above mentioned U.S.Pat. No. 5,260,345 and U.S. Pat. No. 5,268,224.

[0131] BBA and Corovin/BBA nonwovens were obtained form BBA, Greenville,S.C.

[0132] BOUNTY® paper towels were obtained from The Procter & Gamble Co.,Cincinnati, Ohio.

[0133] REYNOLD'S metal foil products were obtained from Reynold's MetalProducts company.

[0134] 3M products were obtained from 3M, Minneapolis, Minn.

[0135] For the materials shown below, the basis weight is expressed ingrams per square meter (gsm). Low density polyethylene is denoted“LDPE”; polypropylene is denoted as “PP”; and polyethylene is denoted as“PE”. Spunbond is denoted as “SB”. TABLE 1 Examples of Laminate Webs ofthe Present Invention Roller Temp. Anvil/ Pitch/ Pattern DOE Example No.Layer 1 Layer 2 Layer 3 Layer 4 Layer 5 (deg. F.) (inches) 1 30 gsm LDPE42 gsm 30 gsm LDPE 250/270 SB nonwoven BOUNTY ® SB nonwoven from PaperTowel from Corovin/BBA Corovin/BBA 2 30 gsm LDPE 42 gsm 42 gsm 30 gsmLDPE 250/270 0.200/ SB nonwoven BOUNTY ® BOUNTY ® SB nonwoven 0.300 fromPaper Towel Paper Towel from Corovin/BBA Corovin/BBA 3 30 gsm LDPE 42gsm 30 gsm LDPE 250/270 0.060/ SB nonwoven BOUNTY ® SB nonwoven 0.850from Paper Towel from Corovin/BBA Corovin/BBA 4 80/20 (PE/ 23 gsm PE50/50 (PE/ 275/295 PP) 30 gsm film from PP) 30 gsm SB nonwoven Clopay SBnonwoven from BBA from BBA 5 80/20 (PE/ 23 gsm PE 50/50 (PE/ 275/2950.200/ PP) 30 gsm film from PP) 30 gsm 0.300 SB nonwoven Clopay SBnonwoven from BBA from BBA 6 80/20 (PE/ 42 gsm 23 gsm PE 50/50 (PE/275/295 PP) 30 gsm BOUNTY ® film from PP) 30 gsm SB nonwoven Paper TowelClopay SB nonwoven from BBA from BBA 7 80/20 (PE/ 42 gsm 23 gsm PE 50/50(PE/ 275/295 0.200/ PP) 30 gsm BOUNTY ® film from PP) 30 gsm 0.300 SBnonwoven Paper Towel Clopay SB nonwoven from BBA from BBA 8 30 gsm LDPEM77 spray REYNOLDS ® M77 spray 30 gsm LDPE 275/295 0.060/ SB nonwovenadhesive from 65 gsm adhesive from SB nonwoven 0.850 from 3M aluminumfoil 3M from Corovin/BBA approx. 13 approx. 13 Corovin/BBA gsm gsm 9 30gsm LDPE 88 gsm 42 gsm 30 gsm LDPE 250/270 0.200/ SB nonwovenelastomeric BOUNTY ® SB nonwoven 0.300 from formed film Paper Towel fromCorovin/BBA from Tredegar Corovin/BBA 10 30 gsm LDPE Spray hot 62 gsmHigh Spray hot 30 gsm LDPE 250/270 0.200/ SB nonwoven melt adhesiveInternal Phase melt adhesive SB nonwoven 0.300 from from Ato- Emulsionfrom Ato- from Corovin/BBA Findley open cell Findley Corovin/BBA approx.12 foam approx. 12 gsm gsm 11 27 gsm high 42 gsm 60 gsm 295/350 0.060/elongation BOUNTY ® laminate of 0.110 carded PP Paper Towel 80/20 50/50nonwoven (PE/PP) from BBA nonwoven from BBA

[0136] The laminate webs of the present invention may be utilized inmany varied applications. For example, the relatively low cost ofnonwoven, paper and film materials makes the laminates ideally suitedfor disposable articles.

[0137] The laminates of the present invention can also be useful inabsorbent medical applications such as medical gauze or absorbentsurgical drape. A medical gauze can be made by forming a laminate from afirst outer layer of nonwoven material such as 30 gsm LDPE SB nonwovenfrom Corovin/BBA, an inner layer comprising a 42 gsm Bounty™ paper toweland a second outer nonwoven of 30 gsm LDPE SB. Apertures within thelaminate would provide a path for air to flow to the wound to facilitatehealing, while the inner Bounty™ layer would pull fluid away from thegauze surface to help keep the wound clean. The same laminate asdescribed above would also be useful as an absorbent surgical drape. Thenonwoven outer layers would prevent cellulose fibers from the absorbentBounty™ inner layer from contaminating the incision area during asurgical procedure. In both the medical gauze and surgical drapeexamples, the outer nonwoven layers could be treated to be hydrophobic,hydrophilic or to have different surface energies on each side. In thecase where one nonwoven outer layer is more hydrophilic than the othernonwoven outer layer, the resulting medical gauze or surgical drapewould have one side that is more likely to absorb the fluid and anopposite side that is more likely to stay dry.

[0138] Laminates of the present invention can be useful for beddingapplications, such as blankets, sheets and pillowcases. A blanket can beformed from a first outer layer of nonwoven material such as 30 gsm LDPESB nonwoven from Corovin/BBA, one or more inner layers comprising amacroscopically formed film such as Always Dri-weave™ Topsheet and asecond outer nonwoven of 30 gsm LDPE SB. The formed film in the centerprovides the required bulk to the blanket, while the outer nonwovensprovide the required softness. Apertured versions of this laminateresemble the look and feel of a loose knit. Alternate stretching processconditions can be used to form smaller apertures or a non-aperturedversion of the laminate that may be more suitable for sheets andpillowcases. The inner layer can be replaced with a 23 gsm PE flat filmfrom Clopay to reduce bulk for the sheet and pillowcase applications.The outer nonwovens may be formed from fibers with a high melttemperature, such as Polyester or Nylon, for bedding applications thatmust be able to be washed and dried several times throughout the life ofthe product.

[0139] Other suitable uses for laminates of the present invention arefor use as flexible carrying implement, such as a laundry bag, aswim/beach bag, a garment bag or a purse. The laminate can be formedfrom a first outer layer of 30 gsm PET/PET Bicomponent carded IR bondednonwoven from HDK Industries, an inner layer that could be any number ofnonwovens, films, foils or knitted/woven materials, and a second outernonwoven of 30 gsm PET/PET Bicomponent. The outer nonwovens provide therequired hand feel and durability, while the inner layer providesadditional strength and decorative aesthetics. The layers of thelaminate may be, but are generally not absorbent, so as to serve as abarrier between the contents in the bag and the outside environment. Thelaminate may or may not be apertured. If the laminate is apertured, theaperture size and spacing may vary from very open (i.e., for a laundrybag) to very closed (i.e., for a purse).

[0140] Alternative uses of the laminates of the present invention areuseful for absorbent kitchen and bathroom implements such as a dishtowel, a scrub pad, a sponge, a bath/hand towel or a bath rug. In thecases of the dish towel, bath/hand towel and the bath rug, the laminatecan be formed from a first outer layer of a 30 gsm 70% Bicomponent(PE/PP)/30% Viscose Rayon carded TPB nonwoven from PGI, one or moreinner layers of 42 gsm Bounty™ paper towel and a second outer nonwovenof 30 gsm 70/30 Bico./Rayon carded TPB. The laminate may or may not beapertured, and the outer nonwovens may be formed with synthetic fiberswith a high melt temperature, such as Polyester or Nylon, for towels andrugs that are meant to be more durable than disposable. In the cases ofa scrub pad or sponge, the laminate of the present invention may serveas the entire implement or it may be a component of the implement, forexample the scrubbing side or the absorbent side. A laminate for asponge may be formed from a first outer layer of a 30 gsm 70%Bicomponent (PE/PP)/30% Viscose Rayon carded TPB nonwoven from PGI, aninner layer of 85 gsm high loft batting (30% PET/70% PE/PET Bico.) and asecond outer nonwoven of 30 gsm 70/30 Bico./Rayon carded TPB. Thelaminate may be nonapertured, or it may have apertures to promote theformation of suds in soapy water. The laminate may have surfactantimpregnated within or coated onto the surface of any of the layers. Theinner batting may be sided (i.e., printed PE dots on one side) such thatthe resultant laminate also has sides suited for different tasks (i.e.,scrubbing vs. wiping).

[0141] Tablecloths, placemats and the like are other suitable kitchenimplements for laminates of the present invention. The laminate can beformed from a first outer layer of nonwoven material such as 30 gsm LDPESB nonwoven from Corovin/BBA, an inner layer comprising a 42 gsm Bounty™paper towel and a second outer layer of 23 gsm PE film from Clopay. Thelaminate may be non-apertured to maximize protection of the tablesurface or apertured to form an aesthetically pleasing pattern. Theouter layers need not be different (i.e., both nonwovens or both films)and the inner layer need not be absorbent (i.e., could be any number ofnonwovens, films, foils, foams or knitted/woven materials). All layersmay be formed with higher melt point materials, such as Polyester orNylon, if the article must be washed and dried several times throughoutthe course of its life.

[0142] Laminates of the present invention can also be useful asdecorative coverings for gifts (wrap, bags, bows, etc.) and home accentitems (lamp shades, picture frames, photo albums, etc.) The laminate maybe formed from a first outer layer of nonwoven such as 30 gsm PET/PETBicomponent carded IR bonded nonwoven from HDK Industries, an innerlayer comprising any number of papers (including commercial gift wrappaper), nonwovens, films, foils, foams or knitted/woven materials and asecond outer nonwoven of 30 gsm PET/PET Bicomponent. The laminate may benon-apertured or apertured to form an aesthetically pleasing pattern.Alternately, the outer layers can be a knitted/woven material (i.e., anopen weave PET athletic mesh) that is thermally bonded together throughan inner layer to form a laminate of the present invention.

[0143] A laminate web of the present invention can find use in articlesfor the pet industry such as pet placemats, pet absorbent liners andcoverings for pet beds. The laminate may be formed from a first outerlayer of nonwoven such as 30 gsm PET/PET Bicomponent carded IR bondednonwoven from HDK Industries, an inner layer comprising one or morelayers of 42 gsm Bounty™ paper towel and a second outer nonwoven of 30gsm PET/PET Bicomponent. The laminate may be non-apertured or apertured.Either of the outer nonwoven layers or the inner paper layer may beprinted/dyed to impart color or design to the laminate.

[0144] Disposable bed pads are another suitable bedding application forthe laminates of the present invention. The laminate may be formed froma first outer layer of nonwoven material such as 30 gsm LDPE SB nonwovenfrom Corovin/BBA, an inner layer comprising a 42 gsm Bounty™ paper toweland a second outer layer of 23 gsm PE flat film from Clopay. The flatfilm would be placed against the bed, while the soft nonwoven side wouldbe placed against the skin. The laminate would most likely benonapertured to prevent fluid leak though, but could contain smallapertures to promote air and moisture permeability. Alternately, amicroporous flat film could be used to impart breathable characteristicsto the non-apertured laminate.

[0145] The laminates of the present invention can also be useful inconstruction/industrial applications such as a wall reinforcement/patch,landfill liners and safety fencing/netting. This laminate may be formedfrom a first outer layer of nonwoven material such as 30 gsm PET/PETBicomponent carded IR bonded nonwoven from HDK Industries, an innerlayer of TYVEK® from DuPont, and a second outer nonwoven of 30 gsmPET/PET Bicomponent. The laminate may be non-apertured or apertured. Theresult is a soft, flexible laminate with the known strengthcharacteristics of TYVEK®.

[0146] Signage materials are also uses of the laminates of the presentinvention. The laminate may be formed from a first outer layer ofnonwoven material such as 30 gsm LDPE SB nonwoven from Corovin/BBA, aninner layer comprising a 42 gsm Bounty™ paper towel and a second outernonwoven of 30 gsm LDPE SB. The inner layer of Bounty™ can be printed onone or both sides with the desired text, designs and logo that can beseen through the outer nonwoven layers. The outer nonwoven layers alsoprotect the inner Bounty™ paper layer and give it additional strength.The laminate may be nonapertured or apertured. However, an aperturedversion of the laminate gives the additional advantage of providing apath for wind/air flow such that the sign is not damaged byenvironmental wind conditions.

[0147] The laminates of the present invention are also useful asflexible, soft coverings over rigid items such as baby care accessories(wet wipe containers, bottle caps, etc.) and office furnishings (armrests, keyboard wrist supports, etc.) The laminate may be formed from afirst outer layer of nonwoven material such as 30 gsm LDPE SB nonwovenfrom Corovin/BBA, one or more inner layers comprising a macroscopicallyformed film such as Always Dri-weave™ Topsheet and a second outernonwoven of 30 gsm LDPE SB. The formed film layer(s) in the centerprovides the required bulk and compression characteristics, while theouter layers provide the required softness for skin contact, babyteething, etc. Alternately, the inner layer can comprise a foam materialfor additional softness and compressibility.

[0148] The laminates of the present invention can find use as fabricbackings for carpets and rigid office furniture, such as chairs. Thelaminates may be formed from a first outer nonwoven such as 30 gsmPET/PET Bicomponent carded IR bonded nonwoven from HDK Industries, aninner layer of TYVEK® from DuPont, and a second outer nonwoven of 30 gsmPET/PET Bicomponent. Advantages of the laminate include inexpensiveporosity via the (optional) apertures, and a strong yet flexible webwell suited for industrial backing. Alternately, one or both of theouter nonwovens can be replaced with a tacky film to impart slipresistance characteristics, or the inner layer can be replaced with anelastomer such as an 88 gsm elastomeric formed film from Tredegar and/ora foam to impart stretch/recovery and/or compressibility characteristicsto the web.

[0149] Laminates of the present invention could also be used as fabricsfor clothing with a unique combination of properties. One example isbreathable yet impervious to fluid and flexible fabrics that can becustom painted, drawn, or printed on. A breathable yet fluid imperviousfabric laminate may be formed from a first outer nonwoven such as 30 gsmPET/PET Bicomponent carded IR bonded nonwoven from HDK Industries, aninner layer of NUBS breathable yet fluid impervious film from P&G, and asecond outer nonwoven of 30 gsm PET/PET Bicomponent. The laminate hasadvantages of increased flexibility and breathability vs. gluedlaminates. A flexible fabric that can be custom painted/drawn/printedmay be formed from a first outer nonwoven such as 30 gsm PET/PETBicomponent carded IR bonded nonwoven from HDK Industries, an innerlayer comprising a 42 gsm Bounty™ paper towel, and a second outernonwoven of 30 gsm PET/PET Bicomponent. The inner layer of Bounty™ maybe pre-printed with any conceivable text, design or logo prior tolamination that will show through the outer nonwovens. Alternately, theinner paper layer may be non-printed, and the composite may be paintedor drawn upon after lamination (i.e., for children's art/playactivities). The laminate may be non-apertured or apertured. The outernonwoven layers provide a soft feel, the inner paper layer retains thecolor (paint, ink, etc.) and the combined laminate has the flexibilityand strength of traditional knitted/woven fabrics.

[0150] Alternative uses of the laminates of the present inventioninclude providing an inexpensive source of cooling in locations wheretraditional air conditioners are not available or practical. Thelaminate may be formed from a first outer layer of nonwoven materialsuch as 30 gsm LDPE SB nonwoven from Corovin/BBA, an inner layercomprising a 42 gsm Bounty™ paper towel and a second outer nonwoven of30 gsm LDPE SB. The laminate may be non-apertured or apertured, althoughan apertured version of the laminate is preferable in order to maximizesurface area. The cooling system works by dipping one end of thelaminate into a trough of water and hanging the opposite end of thelaminate over an air flow exposed area, such as an open window.Alternately, the source of air flow may be artificial, such as a fan.The water from the trough wicks within the laminate via the inner paperlayer, and the cooling effect comes from the evaporation of the waterfrom the laminate into the surrounding air.

[0151] Other applications of the present invention include the use ofconductive and sensorized laminates used as floor coverings. Futureoffices and homes are envisioned to have “smart” capabilities, able tosense the number and location of occupants. These conductive,textile-like laminates of the present invention can be used underexisting carpets or incorporated into area rugs to be used as part of anintegrated sensor system. Several position detector techniques could beused along with laminates of the present invention, for example,creating an X-Y array of the materials so that intersection points areformed. Upon application of foot pressure, the change in capacitance atthe intersection points can be detected with the appropriate sensortechnology. It is believed that use of such laminates of the presentinvention permit larger widths of materials to be produced, consistentwith floor covering dimensions, and at much lower cost than currentlyavailable materials.

[0152] The combination of breathability and conductivity of thelaminates of the present invention is well suited for incorporation intoclothing. One skilled in the art can imagine a variety of electronicpossibilities which can be enabled via the incorporation of such lowcost, cloth-like conductive materials. Conductive laminates of thepresent invention can be incorporated into clothing to provideinteractive capabilities. For example, when such laminates are sewn intochildren's clothes along with the appropriate capacitively coupled audiocircuitry, touching the clothing with various pressures and locationscan produce varying audio tones for amusement.

[0153] Laminates of the present invention can find use as a convenientway of forming dough or other edible materials. The laminate may beformed from a first outer layer of nonwoven material such as 30 gsm LDPESB nonwoven from Corovin/BBA, an inner layer of dough and a second outernonwoven of27 gsm high elongation carded PP nonwoven from BBA. The outernonwovens are purposefully chosen to have different chemicalcompositions that, with the regulation of calendaring heat and pressure,as well as inner dough layer thickness, will result in a weak bondbetween the outer nonwovens. The laminate may be non-apertured orapertured, although an apertured version of the laminate is preferableto give the dough a decorative shape. Ease of handling is a majorbenefit of the laminated dough, both in processing (cutting, packaging,etc.) and for consumers. Once the consumer removes the laminated doughfrom the package, the outer nonwovens can easily be removed, exposingthe pre-formed dough. Alternately, the outer nonwovens can be starchbonded edible webs that can be used in this process to help form theinner dough layer, but which do not have to be removed by the consumerprior to cooking and/or consumption.

[0154] Another use for the laminates of the present invention is for useas an absorbent food pad. This thin absorbent pad is commonly placedbelow the food article to absorb any standing fluids in a packaged foodproduct. Perishable food, particularly meats and poultry, are often soldwith an absorbent pad placed between the perishable food and a tray. Theabsorbent pad will absorb any standing fluids, such as blood or otherfluids which may escape from the packaged food. The laminate web used tomake the absorbent food pad could be of any of the laminates described.Particularly useful are laminate webs having a highly absorbent centrallayer, such as single or multiple layers of Bounty Paper towels or airlaid fiber core containing super absorbent fibers or super absorbentparticles. The outer layers may be any suitable film or nonwoven whichallows the fluid to be absorbed by the central layer. The outer layermay or may not be apertured.

[0155] Laminates of the present invention could also be used to makeclean room wipes. A highly absorbent layer is used as the center layerand the outer layers are comprised of fluid control layers that wouldallow liquid passage into the absorbent center layer without releasinglint. This product would be desired over other products in which theabsorbent material, commonly comprised of short fibers (cellulose),leaves behind particles or lint after cleaning. In the laminate of thepresent invention, the absorbent material is encapsulated by the outerlayers thereby reducing the amount of lint left behind and controllingthe fluid flow properties. Suitable outer layer materials includeTredegar 100 mesh LLDPE film, Tredegar CPM, Donalow Phillic SB PE, andother similar materials. The absorbent center layer may be Bounty™ papertowel or other absorbent material. The laminate may be non-apertured orapertured.

[0156] Tack cloths are another suitable use for laminates of the presentinvention. Tack cloths are used primarily to pick up small particlesthrough mechanical entanglement or surface attraction (electrostatic oradhesive). Outer layer materials which high surface areas are desired.An apertured outer layer or apertured laminate is preferred as theapertures may form small pockets or void spaces which entrap particles.Materials with the correct electrostatic nature are preferred.

[0157] While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An absorbent food pad comprising a laminate webcomprising: a) a first web; b) a second web joint to said first web in aface-to-face relationship at a plurality of discrete bond sites, thefirst and second webs forming an interior region therebetween: c) saidbond site defining an elongated melt weakened region having an aspectratio of at least about 2 and having a longitudinal axis oriented in afirst direction and a transverse axis oriented in a second directionorthogonal to said first direction; and d) a third material involved insaid discrete bond sites and substantially filling said interior region.2. A clean room wipe comprising a laminate web comprising: a) a firstweb; b) a second web joint to said first web in a face-to-facerelationship at a plurality of discrete bond sites, the first and secondwebs forming an interior region therebetween: c) said bond site definingan elongated melt weakened region having an aspect ratio of at leastabout 2 and having a longitudinal axis oriented in a first direction anda transverse axis oriented in a second direction orthogonal to saidfirst direction; and d) a third material involved in said discrete bondsites and substantially filling said interior region.
 3. A tack clothcomprising a laminate web comprising: a) a first web; b) a second webjoint to said first web in a face-to-face relationship at a plurality ofdiscrete bond sites, the first and second webs forming an interiorregion therebetween: c) said bond site defining an elongated meltweakened region having an aspect ratio of at least about 2 and having alongitudinal axis oriented in a first direction and a transverse axisoriented in a second direction orthogonal to said first direction; andd) a third material involved in said discrete bond sites andsubstantially filling said interior region.